Hermetically sealed locking retractor

ABSTRACT

A method is provided for sealing locking components of a retractor, wherein the locking components cooperate with a spool shaft extending from, and rotatable with, a rotatable spool of the retractor to selectively lock rotation of the spool. The method includes mounting a base of an open-ended housing to the retractor with the spool shaft accessible via an opening in the base when so mounted, positioning a sealing member to extend about and engage a periphery of the opening and to also extend about and engage a periphery of the spool shaft, operatively arranging the locking components within the interior of the housing, and hermetically sealing a cover to the open end of the housing after the housing is mounted to the retractor. The sealing member engages the peripheries of the first opening and the spool shaft and blocks ingress of moisture and particles to the locking components.

CROSS-REFERENCE TO RELATED U.S. APPLICATION

This patent application is a division of U.S. patent application Ser.No. 14/001,369, filed Aug. 23, 2013, which is the U.S. national phase ofInternational Application No. PCT/US2012/027444, filed Mar. 2, 2012,which claims the benefit of, and priority to, U.S. provisional patentapplication Ser. No. 61/448,262, filed Mar. 2, 2011, the disclosures ofwhich are all expressly incorporated herein by reference.

FIELD OF THE INVENTION

The present invention relates generally to locking retractors, and morespecifically to apparatuses and methods for hermetically sealing lockingcomponents of such retractors.

BACKGROUND

Locking retractors are known, and operate to lock under variousoperating conditions to prevent movement of a web attached thereto. Forexample, an automatic locking retractor (ALR) may operate toautomatically lock after slack in the web is taken up by the retractorfollowing pay out of the web, e.g., after attachment of the web toanother structure such as a tongue or buckle. An emergency lockingretractor (ELR), on the other hand, may lock only under certainemergency conditions such as during rapid deceleration and/or vehicleimpact. Conventional embodiments of such retractors are susceptible tothe ingress of moisture and particulate matter into the lockingcomponents, which could compromise the locking operation of such lockingcomponents. It is therefore desirable to provide a retractor in whichthe locking components are sealed from moisture and particulate matteringress.

SUMMARY

The present invention may comprise one or more of the features recitedin the attached claims, and/or one or more of the following features andcombinations thereof. A method is provided for hermetically sealinglocking components of a retractor, wherein the locking componentscooperate with a spool shaft extending from a rotatable spool of theretractor to selectively lock rotation of the spool. The method maycomprise mounting a base of an open-ended housing to the retractor,wherein the housing may define a first opening through the base into aninterior of the housing, and the spool shaft is accessible via the firstopening when the base of the housing is mounted to the retractor,positioning a first sealing member about the first opening such that thefirst sealing member forms a hermetic seal between the spool shaft andthe first opening, operatively arranging the locking components withinthe interior of the housing, and hermetically sealing a cover to theopen end of the housing after the housing is mounted to the retractor,the first sealing member is positioned about the first opening and thelocking components are operatively arranged within the interior of thehousing.

The foregoing method may further include the subject matter of any oneand/or any combination of the following 11 paragraphs.

Positioning the first sealing member about the first opening maycomprise positioning the first sealing member such that the firstsealing member engages the housing about the first opening and alsoengages the spool shaft circumferentially about the spool shaft when thehousing is mounted to the retractor such that the first sealing memberforms the hermetic seal between the first opening of the housing and thespool shaft.

The housing may define a channel extending into the base of the housingabout the first opening, the channel sized to receive and retain thereinthe first sealing member, and positioning the first sealing member aboutthe first opening may comprise inserting the first sealing member intothe channel.

The retractor may comprise a frame defining a frame sidewall throughwhich the spool shaft extends, and mounting the base of the open-endedhousing to the retractor may comprise mounting the base of theopen-ended housing to the frame sidewall with an exterior surface of thebase opposite to the interior of the housing in contact with the framesidewall.

The frame sidewall and the base of the open-ended housing may eachdefine at least one mounting aperture therethrough and the cover definesat least one mounting aperture therein, and mounting the base of theopen-ended housing to the retractor may comprise passing at least onefixation member through the at least one mounting aperture definedthrough the frame sidewall and through the at least one mountingaperture defined through the base of the open-ended housing and securingthe at least one fixation element within the at least one mountingaperture defined in the cover to thereby secure the housing and thecover, with the locking components operatively arranged within theinterior of the housing, to the frame sidewall of the retractor.

Mounting the base of the open-ended housing to the retractor maycomprise affixing the exterior surface of the base of the housing to theframe sidewall.

Affixing the exterior surface of the base of the housing to the framesidewall may comprise interposing a bonding medium between and incontact with the exterior surface of the base of the housing and theframe sidewall.

The retractor may include a locking bar movably mounted to the framesidewall and engageable with the spool to lock rotation of the spoolrelative to the frame sidewall, and wherein the locking componentscontrol a position of the locking bar to selectively lock the spoolrelative to the frame sidewall. The housing may define a second opening,separate from the first opening, through the base, and one end of thelocking bar may be accessible via the second opening when the base ofthe housing is mounted to the retractor. The method may further comprisepositioning a second sealing member about the second opening, andmounting one of the locking components to the one end of the locking barsuch that the second sealing member forms a hermetic seal between theone of the locking components and the second opening. Hermeticallysealing a cover to the open end of the housing may comprise hermeticallysealing the cover to the open end of the housing after the housing ismounted to the retractor, the first sealing member is positioned aboutthe first opening, the second sealing member is positioned about thesecond opening, the one of the locking components is mounted to the oneend of the locking bar through the second opening and remaining ones ofthe locking components are operatively arranged within the interior ofthe housing.

Positioning the second sealing member about the second opening maycomprise positioning the second sealing member such that the secondsealing member engages the housing about the second opening and alsoengages the one of the locking components when the one of the lockingcomponents is mounted to the one end of the locking bar through thesecond opening such that the second sealing member forms the hermeticseal between the second opening of the housing and the one of thelocking components.

The housing may define a channel extending into the base of the housingabout the second opening, the channel sized to receive and retaintherein the second sealing member, and positioning the second sealingmember about the second opening may comprise inserting the secondsealing member into the channel.

The open-ended housing may comprise a housing sidewall extending fromthe base about an outer perimeter of the housing such that the interiorof the housing is defined between the base of the housing and thehousing sidewall, a free end of the housing sidewall defining one of achannel and a lip. The cover may comprise a cover sidewall extendingabout an outer perimeter thereof, a free end of the cover sidewalldefining the other of a channel and a lip configured complementarily tothe one of the channel and the lip defined by the housing sidewall.Hermetically sealing the cover to the open end of the housing maycomprise bringing the one of the channel and the lip of the housingsidewall into contact with the other of the channel and the lip of thecover, and hermetically sealing the free end of the cover sidewall tothe free end of the housing sidewall such that the lip forms a hermeticseal with the channel.

Hermetically sealing the free end of the cover sidewall to the free endof the housing sidewall may comprise ultrasonically welding the free endof the cover sidewall to the free end of the housing sidewall.

An apparatus is provided for hermetically sealing locking components ofa retractor, wherein the locking components cooperate with a spool shaftextending from a rotatable spool of the retractor to selectively lockrotation of the spool. The apparatus may comprise an open-ended housinghaving a base defining a first opening therethrough into an interior ofthe housing, the base of the housing mounted to the retractor with thespool shaft accessible via the first opening, the locking componentsarranged within the interior of the housing, a first sealing memberpositioned about the first opening to form a hermetic seal between thespool shaft and the first opening, and a cover hermetically attached tothe open end of the housing.

The foregoing apparatus may further include the subject matter of anyone and/or any combination of the following 8 paragraphs.

The housing and the cover may each be formed of a polymer.

The locking components may be configured to cooperate with the spool toform at least one of an emergency locking retractor and an automaticlocking retractor.

The housing may define a first channel extending into the base of thehousing about the first opening, the first channel sized to receive andretain therein the first sealing member. The first sealing member may bepositioned within the first channel such that the first sealing memberengages the housing about the first opening and also engages the spoolshaft about the spool shaft when the housing is mounted to theretractor, the first sealing member thereby forming the hermetic sealbetween the first opening of the housing and the spool shaft.

The first channel may extend into one of an inner surface and an outersurface of the base of the housing about the first opening.

The retractor may further include a frame sidewall through which thespool shaft extends and to which the base of the housing is mounted, anda locking bar movably mounted to the frame sidewall and engageable withthe spool to lock rotation of the spool relative to the frame sidewall,and the locking components may control a position of the locking bar toselectively lock the spool relative to the frame sidewall. The base ofthe housing may further define a second opening therethrough, separatefrom the first opening, such that one end of the locking bar isaccessible through the second opening when the base of the housing ismounted to the frame sidewall, and one of the locking components may bemounted to the one end of the locking bar, and wherein the apparatusfurther comprises a second sealing member positioned about the secondopening such that the second sealing member forms a hermetic sealbetween the one of the locking components and the second opening.

The housing may define a second channel extending into the base of thehousing about the second opening, the second channel sized to receiveand retain therein the second sealing member, and the second sealingmember may be positioned within the second channel such that the secondsealing member engages the housing about the second opening and alsoengages the one of the locking components mounted to the one end of thelocking bar when the housing is mounted to the retractor, the secondsealing member thereby forming the hermetic seal between the secondopening of the housing and the one of the locking components.

The second channel may extend into one of an inner surface and an outersurface of the base of the housing about the second opening.

The locking components may be configured to cooperate with the spool andwith the locking bar to form at least one of an emergency lockingretractor and an automatic locking retractor.

A locking retractor may comprise a frame defining two opposingsidewalls, a spool extending between the two sidewalls and rotatableabout a spool shaft relative to the frame, one end of the spool shaftextending through one of the sidewalls, an open-ended housing having abase defining a first opening therethrough into an interior of thehousing, the base of the housing mounted to the one of the sidewallswith the spool shaft accessible via the first opening of the open-endedhousing, one or more locking components arranged within the interior ofthe housing, the one or more locking components configured to cooperatewith the spool shaft to selectively lock rotation of the spool relativeto the frame, a sealing member positioned about the first opening toform a hermetic seal between the spool shaft and the first opening, anda cover hermetically attached to the open end of the housing with theone or more locking components contained within the interior of thehousing.

The foregoing retractor may further include the subject matter of anyone and/or any combination of the following 4 paragraphs.

The one or more locking components may be configured to cooperate withthe spool shaft to form at least one of an emergency locking retractorand an automatic locking retractor.

The retractor may further comprise at least one ratchet wheel mounted toand rotatable with the spool, a locking bar mounted between the twoopposing sidewalls of the frame, the locking bar movable relative to theframe between a first position in which the locking bar engages the atleast one ratchet wheel and a second position in which the locking bardoes not engage the at least one ratchet wheel, one end of the lockingbar extending through the one of the sidewalls, wherein the base of theopen-ended housing defines a second opening therethrough separate fromthe first opening, and the one end of the locking bar is accessible viathe second opening, and wherein one of the one or more lockingcomponents is mounted to the one end of the locking bar, and a secondsealing member positioned about the second opening such that the secondsealing member forms a hermetic seal between the one of the one or morelocking components and the second opening, wherein the one or morelocking components control the locking bar between the first and secondpositions thereof to selectively lock the spool relative to the framesidewall.

The locking components may be configured to cooperate with the spool andwith the locking bar to form at least one of an emergency lockingretractor and an automatic locking retractor.

The housing and the cover may each be formed of a polymer.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective and partial assembly view of one illustrativeembodiment of an apparatus for hermetically sealing locking componentsof a locking retractor.

FIG. 2 is a perspective view of the bottom or backside of the housing ofFIG. 1 illustrating partial assembly of the apparatus shown in FIG. 1.

FIG. 3A is a plan view of one of the sealing members of the apparatusshown in FIGS. 1 and 2.

FIG. 3B is a cross-section of the sealing member of FIG. 3A viewed alongsection lines 3B-3B.

FIG. 4A is a plan view of the housing of FIGS. 1 and 2 mounted to one ofthe sidewalls of the frame of the retractor illustrated in FIG. 1.

FIG. 4B is a plan view similar to FIG. 4A shown with a sealing memberpositioned in a channel of the housing about the end of the locking barof the retractor.

FIG. 5 is an exploded view of the various locking components of oneillustrative embodiment of the spool locking assembly illustrated inFIG. 1.

FIG. 6 is a perspective view of the locking bar engaging side of thelocking bar engagement member illustrated in FIG. 5.

FIG. 7 is a plan view similar to FIG. 4B shown with the locking barengagement member of FIGS. 5 and 6 mounted to the end of the locking barillustrated in FIG. 4B.

FIG. 8 is a plan view of the bottom or backside of the locking plateillustrated in FIG. 5.

FIG. 9 is a plan view similar to FIG. 7 shown with the locking plate ofFIGS. 5 and 8 mounted within the housing of the apparatus.

FIG. 10 is a perspective view of the apparatus shown with the clutchwheel 52 mounted to the locking plate of FIG. 9 and with the lockingactuator 54 mounted within the housing of the apparatus.

FIG. 11 is a plan view of the inside surface of the cover illustrated inFIG.

FIG. 12 is a perspective view of the apparatus of FIG. 1 as assembled.

FIG. 13 is a perspective and partial assembly view of an alternateembodiment of an apparatus for hermetically sealing locking componentsof a locking retractor.

FIG. 14 is a flowchart of an illustrative process for hermeticallysealing locking components, i.e., a spool locking assembly, of aretractor.

DESCRIPTION OF THE ILLUSTRATIVE EMBODIMENTS

For the purposes of promoting an understanding of the principles of theinvention, reference will now be made to a number of illustrativeembodiments shown in the attached drawings and specific language will beused to describe the same.

Referring now to FIG. 1, an apparatus 10 is illustrated for hermeticallysealing locking components 12 of a retractor 14 to produce ahermetically sealed locking retractor 5. The locking components 12 mayinclude one or more locking components, and the locking components 12make up a spool locking apparatus or assembly. As used herein, the terms“locking components, “spool locking apparatus” and “spool lockingassembly” may be used interchangeably and each such term refers to theone or more locking components 12 which operate to lock rotation of thespool 20 under certain operating conditions of the retractor 5. In oneembodiment, for example, as will be shown and described in detailhereinafter, the spool locking apparatus 12 illustratively includes oneor more locking components that lock rotation of the spool 20 under oneor more “emergency conditions” such that the resulting hermeticallysealed locking retractor 5 is, in such embodiments, a so-calledconventional emergency locking retractor or ELR. In other embodiments,the spool locking apparatus 12 illustratively includes one or morelocking components that automatically lock rotation of the spool 20under one or more “non-emergency conditions” such that the resultinghermetically sealed locking retractor 5 is, in such embodiments, aso-called automatic locking retractor or ALR. In still otherembodiments, the spool locking apparatus 12 illustratively includes oneor more locking components that automatically lock rotation of the spool20 under one or more non-emergency conditions and one or more lockingcomponents that lock rotation of the spool 20 under one or moreemergency conditions such that the resulting hermetically sealed lockingretractor 5 is, in such embodiments, a combination ALR and ELR.

The “emergency conditions” under which the one or more lockingcomponents lock rotation of the spool 20 may include, but are notlimited to, one or more of (1) one or more orientations of the retractor5 relative to the direction of gravity, i.e., relative to earth, (2)when the rotational speed of the spool 20 exceeds a threshold speed,i.e., inertial locking, and (3) when the retractor 5 decelerates at arate that is greater than a deceleration threshold, e.g., during avehicle crash. The “non-emergency conditions” under which the one ormore locking components lock rotation of the spool 20 may include, butare not limited to, automatically locking the spool at a set position ofthe spool 20, e.g., after the spool 20 has traveled a distance in theweb payout direction that corresponds to, for example, extension of apredetermined length of web from the retractor. In some embodiments, thespool 20 may thereafter rotate in the web take-up direction to a desiredposition, e.g., to a desired position of the web, such that the spool 20locks at that desired position and thereafter cannot rotate in the webpayout direction.

For clarity of illustration, the spool locking apparatus 12 isillustrated in FIG. 1 as a single generic structure, although it will beunderstood that depending upon the configuration of the spool lockingapparatus 12, i.e., as between an ELR, an ALR or both, the spool lockingapparatus 12 may be implemented an assembly that includes a plurality oflocking components. Alternatively or additionally, depending upon theconfiguration of the retractor 14 with which the spool locking apparatus12 interfaces, the spool locking apparatus 12 may be configured tooperatively engage one or multiple components of the retractor 14.

In the embodiment illustrated in FIG. 1, the retractor 14 includes aframe 18 having a pair of sidewalls 18A and 18B that extend away from abase 18C of the frame 18. Illustratively, the sidewalls 18A and 18B aresubstantially parallel. In any case, a space is defined between thesidewalls 18A and 18B and a spool 20 is rotatably mounted between thesidewalls 18A and 18B in a conventional manner. One end of aconventional flexible web (not shown) will typically be attached to thespool 20, and such a web will be wrapped around the spool 20 in aconventional manner. A free end (not shown) of the web will generallyextend from the retractor 14, and an engagement member (not shown),e.g., a hook or other conventional engagement member, may be attached tothe free end of the web. A conventional power spring assembly 22, e.g.,a power spring contained within a housing or cover, is attached betweenthe spool 20 and the sidewall 18A of the frame 18. The power spring isconfigured in a conventional manner to apply a rotational biasing forceto the spool 20 in a web take up direction, which rotational biasingforce may be manually overcome when the retractor 14 is not locked bythe locking components 12 from rotating the spool 20 in an opposite webpayout direction to draw web from the spool 20. The hermetically sealingapparatus 10 including the spool locking apparatus 12 contained thereinis illustratively mounted to the opposite sidewall 18B, and the spoollocking apparatus 12 is therefore illustratively hermetically sealed bythe apparatus 10 as will be described in greater detail hereinafter.Hermetic sealing of the locking components 12 by the apparatus 10 blocksingress of moisture and particles to the locking components 12 such thatthe locking components 12 are maintained functional during exposure ofthe retractor 5 to harsh environments such as, for example, dust, dirtand mud, and including full or partial immersion of the retractor 5 inwater that may include various amounts of dirt or mud, e.g., ponds,lakes, streams, ditches, puddles, etc.

A spool shaft 30 is rigidly mounted to the spool 20 such that the shaft30 rotates with the spool 20. The spool shaft 30 extends through thesidewall 18B of the frame 18 and extends outwardly away from thesidewall 18B as shown in FIG. 1. In the embodiment of the retractor 14illustrated in FIG. 1, a conventional locking bar 32 is movably mountedto and between the sidewalls 18A and 18B, and one end 32A of the lockingbar 32 extends through an opening 18D in the sidewall 18B and at leastpartially extends outwardly away from the sidewall 18B. The locking bar32 is conventional and is normally biased, e.g., via a spring (notshown) attached between the locking bar 32 and the frame 18, away fromthe spool 20 so that the spool 20 may rotate in either of the web takeup or web pay out directions. When the retractor 14 is locked, e.g., viathe locking components 12, the locking bar 32 is forced toward the spool20 and engages teeth (not shown) formed on at least one ratchet wheelmounted to the spool 20. In the illustrated embodiment, two such ratchetwheels 34A and 34B are mounted to the spool 20 at opposite ends thereof.In the illustrated embodiment, the locking bar 32 engages the teeth ofthe ratchet wheels 34A and 34B when the retractor 14 is locked, therebypreventing rotational movement of the spool 20 in the web payoutdirection in a conventional manner.

In the embodiment illustrated in FIG. 1, the apparatus 10 forhermetically sealing locking components 12 of the retractor 5 includes ahousing 40, housing cover 42 and two sealing members 44 and 46.Referring now to FIGS. 1 and 2, the housing 40 is illustratively anopen-ended housing having a base 40M defining an inner surface 40A andan outer surface 40B opposite the inner surface 40A. A housing sidewall40C extends outwardly away from the inner surface 40A of the base 40Mabout an outer periphery of the housing 40. The base 40M of the housing40 defines two separate openings 40D and 40E respectively therethrough,and a pocket 40H sized to receive a locking actuator component of thespool locking apparatus 12 as will be illustrated and describedhereinafter. The opening 40D is sized to receive therethrough the spoolshaft 30 and the second opening 40E is sized to provide access to theend 32A of the locking bar 32 when the outer surface 40B of the base 40Mof the housing 40 is mounted to the sidewall 18B of the frame 18. Thehousing 40 is configured such that the openings 40D and 40E align withthe spool shaft 30 and the end 32A of the locking bar 32 respectivelywhen the base 40M of the housing 40 is mounted to the sidewall 18B.

As illustrated by example in FIGS. 1 and 2, the sidewall 18B of theframe 18 and/or the base 40M of the housing 40 may be configured toaccommodate mounting to the other. Such configuration may, for example,facilitate alignment of the housing 40 relative to the sidewall 18B,facilitate mounting of the housing 40 to the sidewall 18B and/oraccommodate one or more features of the housing 40 and/or sidewall 18B.For example, the pocket 40H formed in the base 40M and extending intothe inner surface 40A produces a protrusion 40H from the outer surface40B, and a window 18E is therefore formed through the sidewall 18B ofthe frame 18 which is sized to receive the pocket 40H therein. Afastening site 40J is also illustratively formed on the pocket 40H onthe outer surface 40B of the housing 40, and the fastening site 40J issized to receive therein a fixation member such that an optional cover(not shown) may be placed over the window 18E on the inside surface ofthe sidewall 18B and fixed in place via such a fixation member.

The housing 40 may further include a plate 401 which extends from theouter surface 40B of the base 40M of the hosing 40, which plate 401 mayextend under an indented portion 18J of the frame 18 between thesidewall 18B and the base 18C. The housing 40 may further includeprotrusions 43A and 43B which extend outwardly from the outer or bottomsurface 40B of the housing 40, and the sidewall 18B may define acorresponding pair of openings 18H and 181 therethrough which are sizedto receive therein the protrusions 43A and 43B respectively.Alternatively, either or both of the protrusions may be formed on thesidewall 18B and either or both corresponding openings may be formedinto, but not through, the outer surface 40B of the housing 40.

Generally, the base 40M of the housing 40 is mounted to the retractor14, and more specifically the base 40M of the housing 40 isillustratively mounted to the sidewall 18B of the frame 18 with theouter surface 40B of the base 40M in contact with the outer face of thesidewall 18B. In the embodiment shown in FIGS. 1 and 2, this mounting isillustratively accomplished by passing one or more fixation membersthrough the sidewall 18B, through openings defined through the housing40 and into engagement with the cover 42. In the illustrated example,two openings 18F and 18G are defined through the sidewall 18B of theframe 18, and corresponding openings 41A and 41B are defined through thebase 40M of the housing. As illustrated in FIGS. 1, 4A-4B, 7, 9 and 10,however, the openings 41A and 41B are formed outside of the interior ofthe open-ended housing, which interior is defined and bounded by theinner surface 40A of the base 40A and a continuous inner surface of thesidewall 40C which extends about the periphery of the housing 40. Thenopenings 41A and 41B defined through the housing 40 therefore do notextend through the base 40M into the interior of the housing 40, butrather extend through the base 40M of the housing 40 outside of theinterior of the housing 40.

In any case, the inside surface of the cover 42 defines two fasteningsites (or mounting apertures) 42C and 42D as illustrated by example inFIG. 11. Each of the sites 42C and 42D is configured to receive andengage a corresponding one of two fixation members 25A and 25B. When thehousing 40 is mounted to the retractor 14 with the outer surface 40B ofthe base 40M in contact with the outer surface of the frame sidewall 18Bas illustrated in FIG. 1, the openings 41A and 41B align with theopenings 18F and 18G respectively, and the fixation members 25A and 25Bextend through the aligned opening pairs 18F, 41A and 18G, 41Brespectively (as clearly illustrated in FIG. 10). After the lockingcomponents of the spool locking apparatus 12 are operatively arrangedwithin the interior of the housing 40, the cover 42 is placed over theopen end of the housing 40 such that the fastening sites 42C and 42Dalign with the openings 41A and 41B (and with the fixation members 25Aand 25B) respectively. The fixation members 25A and 25B are thenmanipulated to engage the fastening sites 42C and 42D respectively tothereby mount the combination of the housing 40 and the cover 42, withthe spool locking apparatus 12 contained therebetween, to the retractor14, i.e., to the frame sidewall 18B. Illustratively, the housing 40 andthe cover 42 are formed by a moldable synthetic or semi-syntheticorganic solid material such as a polymer or similar material, althoughthis disclosure contemplates that the housing 40 and/or cover 42 may bealternatively formed of one or more additional or other materials.

It will be understood that this disclosure contemplates mounting of thehousing 40 to the frame 18 of the retractor 14 using one or moreadditional or alternative, conventional techniques. As one alternative,or in addition, to the mounting of the housing 40 to the frame sidewall18B as just described, a bonding medium 27 may be interposed between andin contact with the outer surface 40B of the housing 40 and the outersurface of the frame sidewall 18B as illustrated by dashed-linerepresentation in FIG. 1. The bonding medium 27 may be any conventionalmedium which creates a bond between the base 40M of the housing 40 andthe frame sidewall 18B, examples of which include, but should not belimited to, adhesives, resins, and the like. As another alternative, orin addition, to the mounting of the housing 40 to the frame sidewall 18Bas just described and/or to use of a bonding medium 27, the housing 40may be mounted to the frame sidewall 18B using a conventional stakingprocess. In such a process, the protrusions 43A and/or 43B, and/or oneor more additional or alternate protrusions formed on or attached to theouter surface 40B of the housing 40 may be sized and/or configured to bestaked to corresponding openings, e.g., openings 18H and/or 181 and/orone or more additional or alternate openings formed in the framesidewall 18B, to thereby secure the housing 40 to the frame sidewall18B. One or more conventional mounting structures and/or processes mayadditionally or alternatively be used to mount the housing 40 to theframe 18 of the retractor 14, and any such structures and/or processesare contemplated by this disclosure.

Referring still to FIGS. 1 and 2, the sealing member 46 is positionedabout the opening 40D defined through the base 40M of the housing 40.The sealing member 46 is illustratively configured to extend about andengage the periphery of the opening 40D and to extend about and engagethe periphery of the spool shaft 30 when the base 40M of the housing 40is mounted to the sidewall 18B of the frame 18 such that a hermetic sealis formed between the housing 40 and the spool shaft 30. In oneembodiment, the sealing member 46 is illustratively a conventional,flexible, e.g., rubber, polymer or the like, annular member. Referringto FIGS. 3A and 3B, plan and cross-sectional views respectively areshown of one illustrative embodiment of the sealing member 46. In theillustrated embodiment, the sealing member 46 is a double ring structurewith an outer annular ring 46A coupled to an inner ring 46D. One end 46Bof the outer annular ring 46A is coextensive with one end 46E of theinner annular ring 46D such that the ends 46B and 46E form a continuous,common, flat surface. The opposite end 46C of the outer annular ring 46Aextends beyond the opposite end 46F of the inner annular ring 46D toprovide an offset between the flat ends 46C and 46F of the annular rings46A and 46D respectively. In alternative embodiments, the sealing member46 may be a single annular sealing member, or a conventional quad ring,which may be flexible or semi-flexible, although this disclosurecontemplates alternative embodiments in which the sealing member 46 isnon-annular, non-flexible and/or is formed of one or more additional oralternative materials.

Referring specifically to FIG. 2, the opening 40D formed through thebase 40M of the housing 40 includes a channel 40F defined and extendinginto the outer surface 40B of the base 40M of the housing 40, and formedabout the periphery of the opening 40D. The channel 40F isillustratively sized to receive and retain therein the sealing member46. In alternative embodiments, the channel 40F may be defined in theinner surface 40A surface of the base 40M of the housing 40 about theperiphery of the opening 40D, or may be formed into the periphery of theopening 40D. In any case, the sealing member 46 is illustrativelyinserted into the channel 40F with the common, flat ends 46B and 46E incontact with the bottom of the channel 40F and with the offset ends 46Cand 46F facing outwardly away from the channel 40F.

Referring now to FIGS. 1, 2, 4A and 4B, the sealing member 44 ispositioned about the opening 40E defined through the base 40M of thehousing 40. The sealing member 44 is illustratively configured to extendabout and engage the periphery of the opening 40E and to extend about,but not engage, the periphery of the end 32A of the locking bar 32 whenthe housing 40 is mounted to the sidewall 18B of the frame 18. In oneembodiment, the sealing member 44 is illustratively a conventional,flexible, e.g., rubber, polymer or the like, annular membersubstantially identical in structure to, but sized differently than, thesealing member 46. Alternatively, the sealing member 44 may be a singleannular sealing member, or a conventional quad ring, and may be flexibleor semi-flexible, although this disclosure contemplates alternativeembodiments in which the sealing member 44 is non-annular, non-flexibleand/or is formed of one or more additional or alternative materials. Inthe illustrated embodiment, the opening 40E includes a channel 400defined in the inner surface 40A of the base 40M of the housing 40 andformed about the periphery of the opening 40E. The channel 400 isillustratively sized to receive and retain therein the sealing member44. In alternative embodiments, the channel 400 may be defined in theouter surface 40B surface of the base 40M of the housing 40 about theperiphery of the opening 40E, or may be formed into the periphery of theopening 40E. In any case, the opening 40E through the base 40M of thehousing 40 is aligned with and extends about the end 32A of the lockingbar 32 when the base 40D of the housing 40 is mounted to the framesidewall 18B as illustrated in FIG. 4A. As illustrated in FIG. 4B, thesealing member 44 is illustratively inserted into the channel 400 withthe offset end of the outer ring in contact with the bottom of thechannel 400 (as shown in FIG. 2) and with the common, flat ends of theinner and outer annular rings facing outwardly away from the channel 400(as shown in FIGS. 1, 4A and 4B).

With the base 40M of the housing 40 mounted to the frame sidewall 18Bbas shown in FIGS. 1, 4A and 4B, the spool shaft 30 illustrativelyextends through the opening 40D defined through the base 40M of thehousing 40 and into the interior of the housing defined and bounded bythe inner surface 40A of the base 40M and the inner surface of thesidewall 40C of the housing 40. In alternative embodiments, the spoolshaft 30 may not extend completely through the opening 40D into theinterior of the housing 40 but may instead terminate at or below thepoint at which the opening 40D opens into the inner surface 40A of thebase 40M of the housing 40. For purposes of this disclosure, the phrase“accessible via” used in relation to the spool shaft 30 and the opening40D formed through the base 40M of the housing 40 should be interpretedto encompass all such embodiments. In particular, the phrase “the spoolshaft accessible via the first opening” should be interpreted to mean(1) that the spool shaft 30 extends into the interior of the housing 40defined and bounded by the inner surface 40A of the base 40M and theinner surface of the sidewall 40C surrounding the housing 40, (2) thatthe spool shaft 30 terminates at the point at which the opening 40Dopens into the inner surface 40A of the base 40M of the housing 40, or(3) that the spool shaft 30 terminates below the point at which theopening 40D opens into the inner surface 40A of the base 40M of thehousing 40.

With the base 40M of the housing 40 mounted to the frame sidewall 18Bbas shown in FIGS. 1, 4A and 4B, the end 32A of the locking bar 32illustratively extends into the opening 40E defined through the base 40Mof the housing 40, but does not clear the top of the channel 40G. Inalternative embodiments, the end 32A of the locking bar 32 may notterminate at or below the top of the channel 400 but may instead extendbeyond the top of the channel 400 into the interior of the housing 40defined and bounded by the inner surface 40A of the base 40M and theinner surface of the sidewall 40C surrounding the housing 40. Forpurposes of this disclosure, the phrase “accessible via” used inrelation to the end 32A of the locking bar 32 and the opening 40E formedthrough the base 40M of the housing 40 should be interpreted toencompass all such embodiments. In particular, the phrase “one end ofthe locking bar accessible via the second opening” should be interpretedto mean (1) that the end 32A if the locking bar 32A extends into theinterior of the housing 40 defined and bounded by the inner surface 40Aof the base 40M and the inner surface of the sidewall 40C surroundingthe housing 40, (2) that the end 32A of the locking bar 32 terminates atthe point at which the opening 40E opens into the inner surface 40A ofthe base 40M of the housing 40, or (3) that the end 32A of the lockingbar 32 terminates below the point at which the opening 40E opens intothe inner surface 40A of the base 40M of the housing 40.

Referring now to FIG. 5, an exploded view is shown of one illustrativeembodiment of the spool locking apparatus 12 illustrating variouslocking components associated therewith. In the illustrated embodiment,the various locking components include a locking bar engagement member48, a locking plate 50, a clutch wheel 52, a locking actuator 54 and alocking plate biasing member 56. Starting with the partially constructedlocking retractor illustrated in FIG. 4B, construction of the spoollocking apparatus 12 relative to the retractor 14 illustrated in FIG. 1using the various locking components illustrated in FIG. 5 will now bedescribed with reference to FIGS. 6-10.

Referring now to FIG. 6, the locking bar engagement member 48 of FIG. 5is shown. The locking bar engagement member 48 illustratively includes abase 48A from which a slotted protrusion 48E extends. Illustratively,the base 48A is generally formed in the shape of a truncated discdefining a recessed edge 48B between truncated ends 48C and 48D of thebase 48A, and a lobe or arm 48G extends from the base 48A opposite therecessed edge 48B. The base 48A defines an annular channel 48F thereinabout an outer annular surface of the slotted protrusion 48E. Thechannel 48F is sized to receive therein in sealing engagement thesealing ring 44 illustrated in FIGS. 1, 2 and 4B. A slot defined in theslotted protrusion 48E is sized and configured to receive therein theend 32A of the locking bar 32 when the base 48A of the locking barengagement member 48 is mounted within the housing 40 by forcing theslotted protrusion 48E into the space of the opening 40E defined by theinner surface of the sealing ring 44 (as shown in FIG. 4B) with the armor lobe 48G oriented toward the spool shaft 30 as illustrated by examplein FIG. 7. Thus positioned, the sealing ring 44 forms a hermetic sealbetween the housing 40 and the locking bar engagement member 48, i.e.,between the channel 400 defined about the opening 40E in the base 40M ofthe housing 40 and the channel 48F defined about the slotted protrusion48E in the base 48A of the locking bar engagement member 48, while alsoallowing the locking bar engagement member 48 to rotate relative to thebase 40M of the housing about the outer surface of the slottedprotrusion 48E. The lobe or arm 48G is configured to engage a movablepost such that movement of the post causes the locking bar engagementmember 48 to rotate relative to the housing 40 and thereby move thelocking bar 32 into and out of engagement with the teeth of the ratchetwheels 34A and 34B attached to the spool 20 of the retractor 14 asdescribed hereinabove.

Referring now to FIGS. 5 and 8, one illustrative embodiment of thelocking plate 50 is shown. The locking plate 50 illustratively defines atop surface 50A (shown in FIG. 5) and an opposite bottom surface orunderside 50B (shown in FIG. 8), and an opening 50E therethrough that issized to be received over the spool shaft 30 onto the base 40M of thehousing 40. The locking plate 50 is configured to be movably mounted tothe base 40M of the housing 40 such that the locking plate 50 isgenerally movable about the spool shaft 30. Referring to FIG. 8, forexample, the underside 50B of the locking plate 50 defines therein anannular channel 50C having a channel opening 50D. The biasing member 56shown in FIG. 5 is illustratively a spring in the form of a single wirehaving one end 56A that is received through an opening (not shown)defined in the underside 50B of the locking plate 50. The body of thewire 56 is forced into the channel 50C formed in the underside 50B ofthe locking plate 50, and the hooked opposite end 56B of the wire 56extends out of the end 50D of the channel 56 as illustrated in FIG. 8.The underside 50B of the locking plate 50 also defines a post 50F thatengages and moves the lobe or arm 48G of the locking bar engagementmember 48 when the locking plate 50 moves about the spool shaft 30 aswill be described in greater detail hereinafter.

Referring now to FIG. 9, the locking plate 50 is shown mounted withinthe housing 50 with the opening 50E engaging ridges defined in the innersurface 40A of the housing 40 and with the hooked end 56B of the biasingwire 56 engaging, e.g., looped around, a protrusion 40L extendingupwardly away from the inner surface 40A of the housing 40. The biasingmember 56 normally biases the locking plate in the position illustratedin FIG. 9, and in this position the locking plate engagement member 48is in the position illustrated in FIGS. 7 and 9. In this position,hereinafter referred to as the unlocked position of the locking bar 32in which the locking bar 32 does not engage the ratchet wheels 34A and34B of the spool 20 and in which the locking bar 32 therefore does notlock rotation of the spool 20, the post 50F defined on the underside 50Bof the locking plate 50 does not exert force on the lobe or arm 48G ofthe locking bar engagement member 48 and the normal bias applied to thelocking bar 32 (discussed hereinabove) therefore maintains the lockingbar in the unlocked position. In this position, web can therefore bepaid out from the spool 20.

During locking conditions of the retractor 14, i.e., when the actuator54 has been actuated as will be described hereinafter, force applied tothe spool 20 in the web payout direction of the spool 20 rotates thelocking plate 50 counterclockwise about the spool shaft 30 against thebias of the biasing member 56, as will be described in greater detailhereinafter. This counterclockwise movement of the locking plate 50causes the post 50F of the movable plate 50 to force the lobe or arm 48Gof the locking bar engagement member 48 downward relative to the housing40 toward the protrusion 40L such that the locking bar engagement member48 moves the locking bar 32 to a locked position in which the lockingbar 32 engages the ratchet wheels 34A and 34B of the spool 20, therebylocking the spool 20 from further rotation in the web payout direction.

Referring again to FIGS. 5 and 9, the top surface 50A of the lockingplate 50 illustratively defines an annular toothed ring 50G about theopening 50E with an annular well defined between the toothed ring 50Gand the opening 50E. This annular well is sized to receive therein theclutch 52 illustrated in FIG. 5. A pawl 50H is mounted to the topsurface 50A of the locking plate 50, and is normally biased away fromthe toothed ring 50G.

Referring now to FIG. 10, the clutch 52 of FIG. 5 has been mounted tothe locking plate 50 and to the spool shaft 30 through the slot in theclutch 52 illustrated in FIGS. 5 and 10. The clutch 52 is illustrativelyan annular member having a number of teeth formed about its outerperiphery. The clutch 52 rotates with the spool shaft 30 relative to thelocking plate 50 which generally remains stationary when the retractor14 is not locked.

In FIG. 10, the locking actuator 54 has also been installed in thepocket 40H formed into the inner surface 40A of the base 40M of thehousing 40. The locking actuator 54 illustratively includes a ball 60and an actuating arm 62 which contacts the pawl 50H under lockingconditions. During non-locking conditions of the retractor 14, the pawl50H is biased away from the teeth of the clutch 52 as described above,and the biased pawl 50H in turn biases the actuating arm 62 toward thelocking actuator 54. During such non-locking conditions, the spool 20may rotate in the web payout direction such that web may be paid outtherefrom. During certain locking conditions of the retractor 14, e.g.,gravity-based and inertial-based locking conditions, the ball 60 movesagainst and forces the actuating arm 62 against the pawl 50H, whichmoves the pawl 50H into contact with the teeth of the clutch 52.Rotation of the spool shaft 30 in the web payout direction under suchconditions brings one of the teeth of the clutch 52 into contact withthe pawl 50H, thereby blocking further rotation of the clutch 52 andlocking the clutch 52 to the locking plate 50. Further rotation of thespool shaft 30 in the web payout direction applies a rotational force tothe combination of the clutch 52 and the locking plate 50 in thecounterclockwise direction against the biasing member 56. When thisrotational force is greater than the biasing force of the biasing member56, the resulting rotational movement of the combination of the clutch52 and the locking plate 50 in the counterclockwise direction causes thepost 50F on the underside of the locking plate 50 to act against andmove the lobe or arm 48G of the locking bar engagement member 48downwardly toward the protrusion 40L of the housing 40. This movement ofthe locking bar engagement member 48, in turn, causes the locking bar 32to move into engagement with the ratchet wheels 34A and 34B of the spool20 to thereby lock the spool 20 in the web payout direction.

Referring now to FIG. 11, a plan view is shown of the inner surface 42Aof one illustrative embodiment of the cover 42 illustrated in FIG. 1.Illustratively, the inner surface 42A defines a protrusion 42E which,when the cover 42 is mounted and sealed to the open end of the housing40, extends over the locking bar engagement member 48 and acts tomaintain the locking bar engagement member 48 in place in the event thelocking bar engagement member 48 moves axially relative to the opening40E through the housing 40. The inner surface 42A also defines aprotrusion 42G with an opening sized to receive therein the protrusion40L of the housing 40 when the cover 42 is mounted and sealed to theopen end of the housing 40. The protrusion 42G maintains the looped end56B of the wire 56 on the protrusion 40L after the cover 42 is mountedto the housing 40. The inner surface 42A also defines another protrusion42H and a lip 421 that extends radially about the inner surface betweenthe protrusions 42G and 42H. The protrusion 42H and the lip 421 bothextend over the locking plate 50 and act to maintain the locking plate50 in place in the event the locking plate 50 moves axially relative tothe spool shaft 30 within the housing 40. The inner surface 42A furtherdefines a pair of protrusions 42J and 42K which extend over oppositeends of the locking actuator 54 and act to maintain the locking actuatorin place within the pocket 40H of the housing 40.

Referring now to FIGS. 10 and 11, the free end of the sidewall 40C ofthe housing 40 illustratively defines a channel or groove 40K therein,and the free end of the cover 42 defines a complementarily configuredlip 42F. The lip 42F is received within the channel 40K when the cover42 is mounted to the open end of the housing 40. Alternatively, the freeend of the sidewall 40C of the housing may define the lip and the freeend of the cover 42 may define the channel. In any case, the channel 40Kand the lip 42F cooperate to form a hermetic seal between the open endof the housing 40 and the cover 42. In one embodiment, for example, aconventional ultrasonic welding process may be employed to cause the lip42F to melt into the channel 40K, thereby hermetically sealing the cover42 to the open end of the housing 40. Alternatively, a bonding medium,e.g., adhesive, may be interposed between and in contact with the lip42F and the channel 40K, or between and in contact with opposing freeends of the cover 42 and the housing 40 in embodiments which do notinclude the channel 40K and the lip 42F, to thereby bond andhermetically seal the cover 42 to the open end of the housing 40. Thoseskilled in the art will recognize other conventional processes andstructures for forming a hermetic seal between the open end of thehousing 40 and the cover 42, and any such other conventional processand/or structure is contemplated by this disclosure. Referring to FIG.12, the resulting retractor 5 with hermetically sealed lockingcomponents is shown with the cover 42 hermetically sealed to the openend of the housing 40, i.e., attached to the end of the sidewall 40C ofthe housing 40.

The concepts of this disclosure may alternatively be used with lockingretractors of the ELR and/or ALR variety in which the locking componentsalone operate to lock the spool shaft 30 from rotating in the web payoutdirection during locking conditions. Referring to FIG. 13, such analternate embodiment is shown in which the retractor 14′ does notinclude a locking bar 32 as illustrated in FIG. 1. In this embodiment,the housing 40′ is modified to omit the opening 40E illustrated in FIG.1, and the sealing member 44 is likewise omitted. The base 40′M of thehousing 40′ therefore defines only a single opening 40′D therethrough,and a single sealing member 46 is configured to extend about and engagethe periphery of the opening 40′D such that the sealing member 46extends about and engages the periphery of the spool shaft 30 when thebase 40′M of the housing 40′ is mounted to the sidewall 18′B of theframe 18′. A hermetic seal is thereby formed between the housing 40′ andthe spool shaft 30, and the cover 42 is hermetically sealed to the openend of the housing 40′ as described above such that the housing 40′ ishermetically sealed from external contamination. In operation, thelocking components 12′ operate in a conventional manner to lock andunlock rotation of the spool 20 in the web payout direction without theaid of a locking bar of the type illustrated in FIG. 1. As analternative to the embodiment illustrated in FIG. 13, the retractor 14′need not omit the locking bar 32. Thus, the locking bar 32 may beincluded as illustrated in FIG. 1, but the spool locking apparatus 12′will not engage or otherwise interface with the locking bar 32. In suchembodiments, the base 40′M may be modified, such as providing a channelbut without providing an opening therethrough, to accommodate anyportion of one end of the locking bar 32 that may extend beyond theouter surface of the frame sidewall 18′B.

In any case, the locking components 12′ alone operate to lock the spool20 from rotating in the web payout direction during locking conditionsin the embodiment illustrated in FIG. 13. In contrast, rotation of thespool 20 in the web payout direction in the embodiment illustrated inFIGS. 1-12 causes the locking components 12 to control the locking bar32 to selectively lock the spool 20 from rotating in the web payoutdirection. Thus, in both of the illustrated embodiments, the lockingcomponents 12, 12′ cooperate with the spool shaft 30 to selectively lockrotation of the spool 20. In the embodiment illustrated in FIGS. 1-12,the locking components 12 further control the position of the lockingbar to selectively lock the spool relative to the frame 18, whereas inthe embodiment illustrated in FIG. 13 the locking components 12′ aloneoperate to selectively lock the spool relative to the frame 18′.

Referring now to FIG. 14, a flowchart is shown of one illustrativeprocess 100 for hermetically sealing locking components of a retractor.It will be understood that in the flowchart illustrated in FIG. 14, thesteps are not necessarily executed in the sequence shown, and that oneor more steps can include or be merged with one or more other steps. Theprocess 100 is applicable to the embodiment illustrated in FIGS. 1-12and also to the embodiment illustrated in FIG. 13. In any case, theprocess 100 begins at step S1 where the base 40M, 40′M is mounted to theretractor frame 18, 18′ using one or more of the mounting techniquesdescribed herein. At step S2, the sealing member(s) 44 and/or 46 is/arepositioned about the opening(s) 40D, 40E, 40′D in the housing 40, 40′.In embodiments which include a locking bar 32 and in which one of thelocking components 12 engages the locking bar 32, such a lockingcomponent is mounted to the locking bar 32 at step S3, shown indashed-line form to indicate that step S3 is executed only in certainembodiments. In any case, the locking components 12, 12′ are operativelyarranged within the housing 40, 40′ at step S4, and at step S5 the cover42 is hermetically sealed to the open end of the housing 40, 40′ usingone or more of the sealing techniques described hereinabove.

While the invention has been illustrated and described in detail in theforegoing drawings and description, the same is to be considered asillustrative and not restrictive in character, it being understood thatonly illustrative embodiments thereof have been shown and described andthat all changes and modifications that come within the spirit of theinvention are desired to be protected. For example, the concepts of thisdisclosure may alternatively still be used with locking retractors inwhich the locking components do not cooperate with the spool shaft 30,but rather control the locking bar 32 to selectively lock the spool 20from rotating in the web payout direction based only on conditions otherthan those associated with rotation of the spool 20. Such conditions mayinclude, for example, but should not be limited to, changes in inertiasensed by an apparatus such as the locking actuator 54 illustrated anddescribed hereinabove, changes in position of the retractor relative tothe direction of gravitational force, and the like. In such anembodiment, for example, the base 40M of the housing 40 will define onlya single opening 40E therethrough with a sealing member 44 configured toextend about and engage the periphery of the opening 40E such that thesealing member 44 forms a hermetic seal between one of the lockingcomponents and the opening 40E of the housing. In this embodiment, theopening 40D illustrated in FIGS. 1-12 can be omitted, as can the sealingmember 46 and the extended spool shaft 30. To the extent the spool shaft30 extends beyond the frame sidewall 18B, the spool locking apparatus 12will not engage or otherwise interface with the spool shaft 30 and insuch embodiments, the base 40M may be modified, such as providing achannel but without providing an opening therethrough, to accommodateany portion of the spool shaft 30 that may extend beyond the outersurface of the frame sidewall 18B. In operation, the locking components12 operate to lock and unlock rotation of the spool shaft 30 in the webpayout direction strictly by controlling movement of the locking bar 32relative to the frame 18.

What is claimed is:
 1. A method of sealing locking components of aretractor, wherein the locking components cooperate with a spool shaftextending from a rotatable spool of the retractor to selectively lockrotation of the spool, and wherein the spool shaft rotates with therotatable spool, the method comprising: mounting a base of an open-endedhousing to the retractor, the housing defining a first opening throughthe base into an interior of the housing, the spool shaft accessible viathe first opening when the base of the housing is mounted to theretractor, positioning a first sealing member to extend about and engagea periphery of the first opening and to also extend about and engage aperiphery of the spool shaft, the first sealing member blocking ingressof moisture and particles to the locking components, operativelyarranging the locking components within the interior of the housing, andhermetically sealing a cover to the open end of the housing after thehousing is mounted to the retractor, the first sealing member engagesthe peripheries of the first opening and the spool shaft, and thelocking components are operatively arranged within the interior of thehousing.
 2. The method of claim 1 wherein positioning the first sealingmember to extend about and engage the periphery of the first openingcomprises positioning the first sealing member such that the firstsealing member engages the housing about the first opening and alsoengages the spool shaft circumferentially about the spool shaft when thehousing is mounted to the retractor such that the first sealing memberforms a seal between the first opening of the housing and the spoolshaft to block the ingress of moisture and particle to the lockingcomponents.
 3. The method of claim 2 wherein the housing defines achannel extending into the base of the housing about the first opening,the channel sized to receive and retain therein the first sealingmember, and wherein positioning the first sealing member to extend aboutand engage the periphery of the first opening comprises inserting thefirst sealing member into the channel.
 4. The method of claim 1 whereinthe retractor comprises a frame defining a frame sidewall through whichthe spool shaft extends, and wherein mounting the base of the open-endedhousing to the retractor comprises mounting the base of the open-endedhousing to the frame sidewall with an exterior surface of the baseopposite to the interior of the housing in contact with the framesidewall.
 5. The method of claim 4 wherein the frame sidewall and thebase of the open-ended housing each define at least one mountingaperture therethrough and the cover defines at least one mountingaperture therein, and wherein mounting the base of the open-endedhousing to the retractor comprises passing at least one fixation memberthrough the at least one mounting aperture defined through the framesidewall and through the at least one mounting aperture defined throughthe base of the open-ended housing and securing the at least onefixation element within the at least one mounting aperture defined inthe cover to thereby secure the housing and the cover, with the lockingcomponents operatively arranged within the interior of the housing, tothe frame sidewall of the retractor.
 6. The method of claim 4 whereinmounting the base of the open-ended housing to the retractor comprisesaffixing the exterior surface of the base of the housing to the framesidewall.
 7. The method of claim 6 wherein affixing the exterior surfaceof the base of the housing to the frame sidewall comprises interposing abonding medium between and in contact with the exterior surface of thebase of the housing and the frame sidewall.
 8. The method of claim 4wherein the retractor includes a locking bar movably mounted to theframe sidewall and engageable with the spool to lock rotation of thespool relative to the frame sidewall, and wherein the locking componentscontrol a position of the locking bar to selectively lock the spoolrelative to the frame sidewall, and wherein the housing defines a secondopening, separate from the first opening, through the base, one end ofthe locking bar accessible via the second opening when the base of thehousing is mounted to the retractor, and wherein the method furthercomprises: positioning a second sealing member to extend about andengage a periphery of the second opening and to also extend about aperiphery of the locking bar to block ingress of moisture and particlesto the locking components, and mounting one of the locking components tothe one end of the locking bar such that the second sealing member formsa seal between the one of the locking components and the second opening,and wherein hermetically sealing a cover to the open end of the housingcomprises hermetically sealing the cover to the open end of the housingafter the housing is mounted to the retractor, the first sealing memberis positioned to-engage the peripheries of the first opening and thespool shaft, the second sealing member is positioned to extend about theperiphery of the locking bar and to also extend about and engage theperiphery of the second opening, the one of the locking components ismounted to the one end of the locking bar through the second opening andremaining ones of the locking components are operatively arranged withinthe interior of the housing.
 9. The method of claim 8 whereinpositioning the second sealing member comprises positioning the secondsealing member such that the second sealing member engages the housingabout the second opening and also engages the one of the lockingcomponents when the one of the locking components is mounted to the oneend of the locking bar through the second opening such that the secondsealing member forms a seal between the second opening of the housingand the one of the locking components to block ingress of moisture andparticles to the one or more locking components.
 10. The method of claim9 wherein the housing defines a channel extending into the base of thehousing about the second opening, the channel sized to receive andretain therein the second sealing member, and wherein positioning thesecond sealing member to extend about and engage the periphery of thesecond opening comprises inserting the second sealing member into thechannel.
 11. The method of claim 1 wherein the open-ended housingcomprises a housing sidewall extending from the base about an outerperimeter of the housing such that the interior of the housing isdefined between the base of the housing and the housing sidewall, a freeend of the housing sidewall defining one of a channel and a lip, andwherein the cover comprises a cover sidewall extending about an outerperimeter thereof, a free end of the cover sidewall defining the otherof a channel and a lip configured complementarily to the one of thechannel and the lip defined by the housing sidewall, and whereinhermetically sealing the cover to the open end of the housing comprises:bringing the one of the channel and the lip of the housing sidewall intocontact with the other of the channel and the lip of the cover, andhermetically sealing the free end of the cover sidewall to the free endof the housing sidewall such that the lip forms a hermetic seal with thechannel.
 12. The method of claim 11 wherein hermetically sealing thefree end of the cover sidewall to the free end of the housing sidewallcomprises ultrasonically welding the free end of the cover sidewall tothe free end of the housing sidewall.